Protective film for a display device, method of manufacturing the display device having the same, and manufacturing apparatus for the protective film

ABSTRACT

An apparatus for manufacturing a bending panel of a display includes a lower mold having a first member on which a target panel is placed, an upper mold disposed adjacent the lower mold and including a second member including a first surface to press a portion of the target panel and a second surface having a first slope with respect to the first surface, and side molds disposed at opposite sides of the lower mold and each having a third member with a third surface complementary to the second surface of the second member. The first slope is smaller than about 90 degrees.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of Korean PatentApplication No. 10-2019-0047751, filed on Apr. 24, 2019, which is herebyincorporated by reference for all purposes as if fully set forth herein.

BACKGROUND Field

Exemplary implementations of the invention relate generally to displaydevices and, more specifically, to a protective film for a displaydevice, a method of manufacturing the display device having the same,and a manufacturing apparatus for a bending panel, such as a protectivefilm, which is capable of preventing the protective film from beingseparated from the display device and improving its reliability.

Discussion of the Background

Recently, various electronic devices, such as a mobile phone, anavigation unit, a digital camera, an e-book, a portable game unit, orvarious terminals, to which a display device, e.g., a liquid crystaldisplay (LCD) or an organic light emitting diode (OLED) is applied, arebeing used with increasing frequency.

Further, electronic devices with displays having curved surfaces havebeen developed and are also being used with increasing frequency.

The above information disclosed in this Background section is only forunderstanding of the background of the inventive concepts, and,therefore, it may contain information that does not constitute priorart.

SUMMARY

Applicant realized that with the increasing development of electronicdevices with displays having curved surfaces, there is a greater need toensure the durability and reliability of each component having a curvedsurface such as bending panels (e.g., a protective film) of a displaydevice.

Bending panels for a display device, such as a protective film,constructed according to the principles and exemplary implementations ofthe invention are capable of being attached to the display panel withoutseparation. For example, according to one of more exemplary embodiments,the protective film is manufactured by an apparatus that bends an outerportion of the protective film before it is coupled to the display panelto reduce the risk of later separation.

Methods of manufacturing the display device according to the principlesand exemplary of the invention are capable of preventing a protectivefilm disposed under a display panel from being separated therefrom andimproving reliability of the display device.

Additional features of the inventive concepts will be set forth in thedescription which follows, and in part will be apparent from thedescription, or may be learned by practice of the inventive concepts.

According to one aspect of the invention, an apparatus for manufacturinga bending panel of a display device includes: a lower mold having afirst member on which a target panel is placed, an upper mold disposedadjacent the lower mold and including a second member including a firstsurface to press a portion of the target panel and a second surfacehaving a first slope with respect to the first surface, and side moldsdisposed at opposite sides of the lower mold and each having a thirdmember with a third surface complementary to the second surface of thesecond member. The first slope is smaller than about 90 degrees.

The first member may include a stage having a receiving portionsubstantially parallel to a plane defined by a first direction and asecond direction intersecting the first direction. The side molds mayinclude a pair of first side molds spaced apart from each other in thefirst direction, and disposed at the opposite sides of the lower mold topress the target panel in the first direction and a pair of second sidemolds spaced apart from each other in the second direction, and disposedat the both sides of the lower mold to press the target panel in thesecond direction

The upper mold may be spaced apart from the lower mold in a thirddirection intersecting the first direction and the second direction. Theupper mold may be configured to press the target panel in the thirddirection.

The second member may include an upper pressing member having a crosssectional shape with an area in a plan view that increases as thedistance in the third direction from the lower mold decreases.

The second member may include a first pressing portion extending in thefirst direction, a second pressing portion extending in the seconddirection, and a third pressing portion disposed between the firstpressing portion and the second pressing portion and having a roundedshape.

The lower mold further may include an outer-bending forming portionconfigured to overlap with the third pressing portion in the planedefined by the first direction and the second direction. Theouter-bending forming portion may have a shape complementary to therounded shape of the third pressing portion.

The third member may include an upper surface supporting an outerportion of the target panel and a side surface to press the target paneland having a second slope with respect to the upper surface. The secondslope may be smaller than about 90 degrees.

The first slope and the second slop may be substantially the same.

The upper mold further may include a first portion to move the secondmember up and down, and the side molds may further include a secondportion to move the side pressing member left and right.

The lower mold may further include one or more biasing members disposedunder the first member, the one or more biasing members being compressedwhen the second member presses against the target panel.

The upper mold further may include an upper plate supporting the secondmember and an upper heater connected to the upper plate and to apply aheat to the upper plate.

The side molds may further include a side plate supporting the thirdmember and a side heater connected to the side plate and to apply heatto the side plate.

According to another aspect of the invention, an apparatus formanufacturing a bending panel includes: a first mold including a firstmember having a first surface substantially parallel to a plane definedby a first direction and a second direction intersecting the firstdirection, a second mold spaced apart from the first mold in a thirddirection intersecting each of the first and second directions andincluding a second member having a second surface substantially parallelto the first surface and a third surface having a slope with respect tothe second surface that is less than about 90 degrees, and a third moldspaced apart from the first mold in the first direction and the seconddirection and including a third member having a fourth surfacecomplementary to the third surface.

According to still another aspect of the invention, method ofmanufacturing a display device includes the steps of: coupling a displaypanel to a first portion of a window member and coupling a protectivefilm to a lower portion of the display panel. The step of coupling ofthe protective film includes the steps of bending both edges of theprotective film by a bending angle of about 90 degrees or more,disposing the bent protective film on the lower portion of the displaypanel, and coupling the protective film to the display panel.

The step of bending of the both edges of the protective film may includeplacing the protective film on a support, pressing an upper portion ofthe protective film to bend the both edges at a first angle, andpressing a side portion bent at the first angle to bend the both edgesat a second angle. The second angle is smaller than the first angle.

An elastic member may be disposed under the support. The step of thepressing of is the upper portion of the protective film may includecompressing the elastic member.

The step of pressing of the upper portion of the protective film mayfurther include the step of indirectly applying heat to the upperportion of the protective film.

The step of pressing of the side portion of the protective film mayfurther include the step of applying a heat to the side portion of theprotective film.

The step of pressing of the side portion of the protective film may beperformed by horizontally moving one or more side pressing members or byrotating the one or more side pressing members.

The step of bending of the both edges of the protective film may furtherinclude the steps of disposing a release film under the protective filmbefore the placing the protective film on the support and removing therelease film before coupling the display panel to the protective film.

The method may further includes the steps of: before the step ofcoupling of the lower portion of the display panel to the protectivefilm, bending outer portions of the window member and the display panelat a third angle greater than the second angle at which the protectivefilm is bent.

According to still another aspect of the invention, protective film fora display device includes: a substantially flat portion disposedsubstantially parallel to a plane defined by a first direction and asecond direction intersecting the first direction and a bent portiondisposed at a side of the substantially flat portion. The bent portionincludes a first bent portion extending in the first direction and asecond bent portion extending in the second direction. Each of an anglebetween the first bent portion and the substantially flat portion and anangle between the second bent portion and the substantially flat portionis less than about 90 degrees.

The bent portion may further include a third bent portion disposedbetween the first bent portion and the second bent portion.

The third bent portion may be disposed between the first bent portionand the second bent portion and have a rounded shape.

A plurality of slits may be disposed between the first bent portion andthe third bent portion and between the second bent portion and the thirdbent portion.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate exemplary embodiments of theinvention, and together with the description serve to explain theinventive concepts.

FIG. 1A is a cross-sectional view of an exemplary embodiment of abending panel manufacturing apparatus constructed according to theprinciples of the invention taken in a first direction.

FIG. 1B is a cross-sectional view of the bending panel manufacturingapparatus of FIG. 1A taken in a second direction normal to the firstdirection.

FIG. 2A is a combined perspective view of an exemplary embodiment of anupper mold of the bending panel manufacturing apparatus of FIG. 1A.

FIG. 2B is an exploded perspective view of an exemplary embodiment ofthe is upper mold of the bending panel manufacturing apparatus of FIG.1A.

FIG. 2C is a front view of an exemplary embodiment of the upper mold ofthe bending panel manufacturing apparatus of FIG. 1A.

FIG. 2D is a side view of an exemplary embodiment of the upper mold ofthe bending panel manufacturing apparatus of FIG. 1A.

FIG. 3A is a combined perspective view of an exemplary embodiment of alower mold of the bending panel manufacturing apparatus of FIG. 1A.

FIG. 3B is an exploded perspective view of an exemplary embodiment ofthe lower mold of the bending panel manufacturing apparatus of FIG. 1A.

FIG. 3C is a top view of an exemplary embodiment of the lower mold ofthe bending panel manufacturing apparatus of FIG. 1A.

FIG. 4A is a perspective view of an exemplary embodiment of a side moldof the bending panel manufacturing apparatus of FIG. 1A.

FIG. 4B is a front view of an exemplary embodiment of the side mold ofthe bending panel manufacturing apparatus of FIG. 1A.

FIG. 4C is a side view of an exemplary embodiment of the side mold ofthe bending panel manufacturing of FIG. 1A.

FIG. 4D is a front view of an exemplary embodiment of a side mold of abending panel manufacturing apparatus of FIG. 1A.

FIG. 5 is a top view of an exemplary embodiment of some components of abending panel manufacturing apparatus of FIG. 1A.

FIG. 6A is a cross-sectional view of another exemplary embodiment of abending panel manufacturing apparatus constructed according to theprinciples of the invention in a first is direction.

FIG. 6B is a cross-sectional view of the bending panel manufacturingapparatus of FIG. 6A taken in a second direction normal to the firstdirection

FIG. 7A is a perspective view of an exemplary embodiment of a bendingpanel constructed according to the principles of the invention in asubstantially flat, planar state.

FIG. 7B is a perspective view of the bending panel of FIG. 7A in a bentstate.

FIG. 7C is a front view of the bending panel of FIG. 7B

FIG. 7D is a side view of the bending panel of FIG. 7B

FIG. 7E is a perspective view of another exemplary embodiment of abending panel constructed according to the principles of the inventionin a substantially flat, planar state.

FIGS. 8A, 8B, 8C, 8D, 8E, 8F, 8G, 8H, and 8I are cross-sectional viewssequentially showing an exemplary method of manufacturing a displaydevice according to the principles of the invention.

FIGS. 9A, 9B, and 9C are cross-sectional views sequentially showing somesteps of another exemplary method of manufacturing a display deviceaccording to the principles of the invention.

FIG. 10 is a cross-sectional view showing a step of still anotherexemplary method of manufacturing a display device according to theprinciples of the invention.

DETAILED DESCRIPTION

In the following description, for the purposes of explanation, numerousspecific details are set forth in order to provide a thoroughunderstanding of various exemplary embodiments or implementations of theinvention. As used herein “embodiments” and “implementations” areinterchangeable words that are non-limiting examples of devices ormethods employing one or more of the inventive concepts disclosedherein. It is apparent, however, that various exemplary embodiments maybe practiced without these specific details or with one or moreequivalent arrangements. In other instances, well-known structures anddevices are shown in block diagram form in order to avoid unnecessarilyobscuring various exemplary embodiments. Further, various exemplaryembodiments may be different, but do not have to be exclusive. Forexample, specific shapes, configurations, and characteristics of anexemplary embodiment may be used or implemented in another exemplaryembodiment without departing from the inventive concepts.

Unless otherwise specified, the illustrated exemplary embodiments are tobe understood as providing exemplary features of varying detail of someways in which the inventive concepts may be implemented in practice.Therefore, unless otherwise specified, the features, components,modules, layers, films, panels, regions, and/or aspects, etc.(hereinafter individually or collectively referred to as “elements”), ofthe various embodiments may be otherwise combined, separated,interchanged, and/or rearranged without departing from the inventiveconcepts.

The use of cross-hatching and/or shading in the accompanying drawings isgenerally provided to clarify boundaries between adjacent elements. Assuch, neither the presence nor the absence of cross-hatching or shadingconveys or indicates any preference or requirement for particularmaterials, material properties, dimensions, proportions, commonalitiesbetween illustrated elements, and/or any other characteristic,attribute, property, etc., of the elements, unless specified. Further,in the accompanying drawings, the size and relative sizes of elementsmay be exaggerated for clarity and/or descriptive purposes. When anexemplary is embodiment may be implemented differently, a specificprocess order may be performed differently from the described order. Forexample, two consecutively described processes may be performedsubstantially at the same time or performed in an order opposite to thedescribed order. Also, like reference numerals denote like elements.

When an element, such as a layer, is referred to as being “on,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, connected to, or coupled to the other element or layer orintervening elements or layers may be present. When, however, an elementor layer is referred to as being “directly on,” “directly connected to,”or “directly coupled to” another element or layer, there are nointervening elements or layers present. To this end, the term“connected” may refer to physical, electrical, and/or fluid connection,with or without intervening elements. Further, the D1-axis, the D2-axis,and the D3-axis are not limited to three axes of a rectangularcoordinate system, such as the x, y, and z-axes, and may be interpretedin a broader sense. For example, the D1-axis, the D2-axis, and theD3-axis may be perpendicular to one another, or may represent differentdirections that are not perpendicular to one another. For the purposesof this disclosure, “at least one of X, Y, and Z” and “at least oneselected from the group consisting of X, Y, and Z” may be construed as Xonly, Y only, Z only, or any combination of two or more of X, Y, and Z,such as, for instance, XYZ, XYY, YZ, and ZZ. As used herein, the term“and/or” includes any and all combinations of one or more of theassociated listed items.

Although the terms “first,” “second,” etc. may be used herein todescribe various types of elements, these elements should not be limitedby these terms. These terms are used to distinguish one element fromanother element. Thus, a first element discussed below could be termed asecond element without departing from the teachings of the disclosure.

Spatially relative terms, such as “beneath,” “below,” “under,” “lower,”“above,” “upper,” “over,” “higher,” “side” (e.g., as in “sidewall”), andthe like, may be used herein for descriptive purposes, and, thereby, todescribe one elements relationship to another element(s) as illustratedin the drawings. Spatially relative terms are intended to encompassdifferent orientations of an apparatus in use, operation, and/ormanufacture in addition to the orientation depicted in the drawings. Forexample, if the apparatus in the drawings is turned over, elementsdescribed as “below” or “beneath” other elements or features would thenbe oriented “above” the other elements or features. Thus, the exemplaryterm “below” can encompass both an orientation of above and below.Furthermore, the apparatus may be otherwise oriented (e.g., rotated 90degrees or at other orientations), and, as such, the spatially relativedescriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing particularembodiments and is not intended to be limiting. As used herein, thesingular forms, “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise. Moreover,the terms “comprises,” “comprising,” “includes,” and/or “including,”when used in this specification, specify the presence of statedfeatures, integers, steps, operations, elements, components, and/orgroups thereof, but do not preclude the presence or addition of one ormore other features, integers, steps, operations, elements, components,and/or groups thereof. It is also noted that, as used herein, the terms“substantially,” “about,” and other similar terms, are used as terms ofapproximation and not as terms of degree, and, as such, are utilized toaccount for inherent deviations in measured, calculated, and/or providedvalues that would be recognized by one of ordinary skill in the art.

Various exemplary embodiments are described herein with reference tosectional is and/or exploded illustrations that are schematicillustrations of idealized exemplary embodiments and/or intermediatestructures. As such, variations from the shapes of the illustrations asa result, for example, of manufacturing techniques and/or tolerances,are to be expected. Thus, exemplary embodiments disclosed herein shouldnot necessarily be construed as limited to the particular illustratedshapes of regions, but are to include deviations in shapes that resultfrom, for instance, manufacturing. In this manner, regions illustratedin the drawings may be schematic in nature and the shapes of theseregions may not reflect actual shapes of regions of a device and, assuch, are not necessarily intended to be limiting.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this disclosure is a part. Terms,such as those defined in commonly used dictionaries, should beinterpreted as having a meaning that is consistent with their meaning inthe context of the relevant art and should not be interpreted in anidealized or overly formal sense, unless expressly so defined herein.

FIG. 1A is a cross-sectional view of an exemplary embodiment of abending panel manufacturing apparatus 10 constructed according to theprinciples of the invention taken in a first direction. FIG. 1B is across-sectional view of the bending panel manufacturing apparatus 10 ofFIG. 1A taken in a second direction normal to the first direction. FIG.1A shows a cross-section substantially parallel to a plane defined by afirst direction DR1 and a third direction DR3 in the bending panelmanufacturing apparatus 10. FIG. 1B shows a cross-section substantiallyparallel to a plane defined by a second direction DR2 and the thirddirection DR3 in the bending panel manufacturing apparatus 10, which isnormal to the first direction.

In describing the bending panel manufacturing apparatus 10 withreference to is FIGS. 1A and 1B, the vertical direction of the bendingpanel manufacturing apparatus 10 is indicated by the third directionDR3. However, directions indicated by the first, second, and thirddirections DR1, DR2, and DR3 are relative to each other, and thus thedirections indicated by the first, second, and third directions DR1,DR2, and DR3 may be changed to other directions. In the followingdescriptions, an expression “when viewed in a plan view” means the caseof being viewed in the third direction DR3. In addition, the term“thickness direction” means the third direction DR3.

Referring to FIGS. 1A and 1B, the bending panel manufacturing apparatus10 includes an upper mold 100, a lower mold 200, and a side mold 300.

The upper mold 100 includes an upper pressing member 101, an upper plate102, and a first moving unit (e.g. a portion of a motor) 103. The uppermold 100 is disposed above the lower mold 200.

The upper pressing member 101 is connected to the upper plate 102 toperform the function of pressing a target panel that is placed on thebending panel manufacturing apparatus 10 to form the panel into adesired shape. In the exemplary embodiment, the target panel is abending panel such as the protective film 1000 shown in FIG. 8A, but isnot limited thereto. For example, the target panel may be any panel,film or other component of the display device having a curved, bent orrounded shape. The upper pressing member 101 is disposed to correspondto an upper portion of a stage 201 of the lower mold 200. The upperpressing member 101 may include various materials without limitation aslong as the materials are suitable to thermoform the target panel usinga heat transmitted from the upper plate 102. For example, the upperpressing member 101 may include a porous material such as siliconcarbide. As another example, the upper pressing member 101 may include ametal material.

The upper plate 102 is connected to the upper pressing member 101 andtransmits the heat from a heater (described subsequently) to the upperpressing member 101. In addition, the upper plate 102 performs thefunction of fixing the positional relationship of respective componentsincluded in the upper mold 100, such as the upper pressing member 101.The upper plate 102 includes a metal material with high thermalconductivity to transmit the heat applied thereto to the upper pressingmember 101.

The first moving unit 103 is connected to the upper plate 102 to movethe upper mold 100 in upper and lower directions. In detail, the firstmoving unit 103 moves the upper plate 102 connected thereto upward anddownward along the third direction DR3 to allow the upper pressingmember 101 connected to the upper plate 102 to move up and down.Accordingly, the upper pressing member 101 presses the target panel,which is placed on the stage 201 of the lower mold 200 disposed underthe upper pressing member 101, downward.

The lower mold 200 includes the stage 201, an elastic member 202, and abody unit 203. The lower mold 200 is disposed under the upper mold 100.The lower mold 200 is spaced apart from the upper mold 100 in the thirddirection DR3.

The stage 201 supports the target panel placed thereon. The stage 201provides a flat surface 201-US (refer to FIG. 3B) substantially parallelto the first direction DR1 and the second direction DR2 to allow thetarget panel to be disposed substantially parallel to the firstdirection DR1 and the second direction DR2 on the flat surface 201-US.The flat surface 201-US defined at the top of the stage 201 may be areceiving portion on which the target panel is disposed. When the upperpressing member 101 moves downward and presses the target panel, thestage 201 moves downward.

The elastic member 202 is disposed under the stage 201 and provides a ispredetermined elastic force to an upward direction of the stage 201. Asthe upper pressing member 101 applies the pressure downward to thetarget panel placed on the stage 201, the elastic member 202 iscompressed. The elastic member 202 may be implemented in various ways aslong as the elastic member 202 provides the elastic force in the upwarddirection of the stage 201. For example, the elastic member 202 may be,but is not limited to, one of more springs.

The body unit 203 accommodates the stage 201 and the elastic member 202therein and fixes the stage 201 such that the stage 201 moves up anddown without being misaligned when being pressed by the upper pressingmember 101. The body unit 203 further includes an outer-bending formingportion (213, refer to FIGS. 3A and 3B) that forms a bending shape at anouter portion of the target panel.

The side mold 300 is disposed at both sides of the lower mold 200. Theside mold 300 includes a pair of first side molds 310 and 320 spacedapart from each other in the first direction DR1 and extending in thesecond direction DR2 shown in FIG. 1A and a pair of second side molds330 and 340 spaced apart from each other in the second direction DR2 andextending in the first direction DR1 shown in FIG. 1B. The pair of firstside molds 310 and 320 spaced apart from each other in the firstdirection DR1 and disposed at a first set of opposite sides of the lowermold 200. The pair of second side molds 330 and 340 spaced apart fromeach other in the second direction DR2 and disposed at a second set ofopposite sides of the lower mold 200.

The pair of first side molds 310 and 320, and the pair of second sidemolds 330 and 340 include respective side pressing members 311, 321,331, and 341, respective side plates 312, 322, 332, and 342, andrespective second moving units 313, 323, 333, and 343. The side pressingmembers 311, 321, 331, and 341 are connected to the side plates 312,322, 332, and 342 is and secondarily press the placed target panel. Indetail, the side pressing members 311, 321, 331, and 341 secondarilypress the target panel that is bent by being primarily pressed by theupper pressing member 101. The side pressing members 311 and 321 of thepair of first side molds 310 and 320 press the target panel in the firstdirection DR1, and the side pressing members 331 and 341 of the pair ofsecond side molds 330 and 340 press the target panel in the seconddirection DR2.

The side pressing members 311, 321, 331, and 341 are respectivelyconnected to the side plates 312, 322, 332, and 342, and the side plates312, 322, 332, and 342 transmit the heat from the heater 314, 324, 334,and 344 shown in FIG. 4A to the side pressing members 311, 321, 331, and341. The side plates 312, 322, 332, and 342 fix the positional betweencomponents included in the side mold 300, e.g., the side pressingmembers 311, 321, 331, and 341. The side plates 312, 322, 332, and 342include a metal material with high thermal conductivity to transmit theheat applied thereto to the side pressing members 311, 321, 331, and341.

The second moving units 313, 323, 333, and 343 are connected to the sideplates 312, 322, 332, and 342 and move the side mold 300 in the firstdirection DR1 and the second direction DR2. In detail, the second movingunits 313, 323, 333, and 343 move the side plates 312, 322, 332, and342, which are connected thereto, left and right along the firstdirection DR1 and the second direction DR2 to allow the side pressingmembers 311, 321, 331, and 341 connected to the side plates 312, 322,332, and 342 to move left and right. Therefore, the side pressingmembers 311, 321, 331, and 341 press the target panel placed on thestage 201 of the lower mold 200 disposed between the pair of first sidemolds 310 and 320, and between the pair of second side molds 330 and 340toward the center of the bending panel manufacturing apparatus.

FIGS. 1A and 1B show a representative example of the upper mold 100 thatmoves downward along the third direction DR3 by the operation of thefirst moving unit 103 and primarily presses the target panel, however,it should not be limited thereto or thereby. That is, a moving unit likethe first moving unit 103 may be included in the lower mold 200 and theside mold 300. In this case, an operation of primarily pressing thetarget panel may be performed by moving the lower mold 200 and the sidemold 300 upward along the third direction DR3 by the moving unitconnected to the lower mold 200 and the side mold 300.

Hereinafter, each component included in the bending panel manufacturingapparatus 10 according to the exemplary embodiment will be described indetail with reference to individual figures.

FIG. 2A is a combined perspective view of an exemplary embodiment of theupper mold 100 of the bending panel manufacturing apparatus of FIG. 1A.FIG. 2B is an exploded perspective view of an exemplary embodiment ofthe upper mold 100 of the bending panel manufacturing apparatus of FIG.1A. FIG. 2C is a front view of an exemplary embodiment of the upper mold100 of the bending panel manufacturing apparatus of FIG. 1. FIG. 2D is aside view of an exemplary embodiment of the upper mold 100 of thebending panel manufacturing apparatus of FIG. 1A.

Referring to FIGS. 2A to 2D, the upper mold 100 according to theexemplary embodiment may include the upper pressing member 101, theupper plate 102, the first moving unit 103, an upper heating heater 104,and an upper temperature sensor 105.

The upper pressing member 101 is connected to the upper plate 102 andhas a shape in which an area on a plane defined by the first directionDR1 and the second direction DR2 increases as the upper pressing member101 gets closer to the lower mold 200 along the is third direction DR3.The upper pressing member 101 may have a trapezoidal shape in crosssection. The upper pressing member 101 may have an inverted taperedshape.

The upper pressing member 101 may include a first pressing portion101-1, a second pressing portion 101-2, and a third pressing portion101-3. The first pressing portion 101-1 may extend in the firstdirection DR1 and may press both ends of the target panel, which arespaced apart from each other in the second direction DR2. The secondpressing portion 101-2 may extend in the second direction DR2 and maypress both ends of the target panel, which are spaced apart from eachother in the first direction DR1. The third pressing portion 101-3 maybe defined between the first pressing portion 101-1 and the secondpressing portion 101-2 and may have a round shape. The third pressingportion 101-3 may press a portion corresponding to a vertex of thetarget panel and may bend the portion in the round shape.

The upper pressing member 101 includes a lower surface 101-US and a sidesurface 101-LS1, 101-LS2. The lower surface 101-US of the upper pressingmember 101 may be a surface that substantially presses the upper portionof the target panel. The side surface 101-LS1, 101-LS2 of the upperpressing member 101 may have a first slope with respect to the lowersurface 101-US of the upper pressing member 101. The side surface101-LS1, 101-LS2 of the upper pressing member 101 may have the firstslope inclined by a first angle θ1 with respect to the lower surface101-US of the upper pressing member 101. The first angle θ1 may be anacute angle. That is, the first angle θ1 may be smaller than about 90degrees.

The upper plate 102 may be connected to the upper pressing member 101,the first moving unit 103, the upper heating heater 104, and the uppertemperature sensor 105, which are included in the upper mold 100, todetermine the positional relationship between them.

The first moving unit 103 may be disposed on the upper plate 102 and maymove is the upper mold 100 up and down along the third direction DR3.The first moving unit 103 may move the upper mold 100 up and down alongthe third direction DR3 using a pneumatic or hydraulic cylinder or othermeans known in the art. As another way, the first moving unit 103 maymove the upper mold 100 up and down along the third direction DR3 usinga mechanical cylinder.

The upper heating heater 104 may be connected to the upper plate 102 andmay apply the heat to the upper plate 102 such that the upper pressingmember 101 thermoforms the target panel using the heat applied thereto.When the upper heating heater 104 applies the heat to the upper plate102, the heat may be adjusted to a temperature suitable forthermoforming the target panel by the upper temperature sensor 105connected to the upper plate 102.

The upper mold 100 may further include a guide pin for the alignmentwith the lower mold when pressing the target panel.

In FIGS. 2A to 2D, the components included in the upper mold 100 haveseparate components, however, they should not be limited thereto orthereby. That is, some components among the components included in theupper mold 100 may have a single unitary form. For example, the upperpressing member 101 may have a shape integrally provided with the upperplate 102.

FIG. 3A is a combined perspective view of an exemplary embodiment of thelower mold 200 of the bending panel manufacturing apparatus of FIG. 1A.FIG. 3B is an exploded perspective view of an exemplary embodiment ofthe lower mold 200 of the bending panel manufacturing apparatus of FIG.1A. FIG. 3C is a top view of an exemplary embodiment of the lower mold200 of the bending panel manufacturing apparatus of FIG. 1A.

Referring to FIGS. 3A to 3C, the lower mold 200 may include the stage201, the is elastic member 202, and the body unit 203.

The stage 201 is disposed at a center of the body unit 203. In FIGS. 3Aand 3B, the stage 201 is shown as being a rectangular parallelepipedshape, however, the shape of the stage 201 should not be limited theretoor thereby. That is, the stage 201 may have various shapes, eachproviding a surface, such as planar, on which the target panel may beplaced. The stage 201 may have a rectangular shape on a plane defined bythe first direction DR1 and the second direction DR2. The stage 201 mayhave a first length d1 in the first direction DR1 and a second length d2in the second direction DR2.

The elastic member 202 is disposed under the stage 201 and provides theelastic force to the stage 201 in the upward direction along the thirddirection DR3. The elastic member 202 may be one or more springs. InFIG. 3B, the lower mold 200 includes nine elastic members 202 as arepresentative example, however, the number of the elastic members 202should not be limited to nine. The number, shape, and arrangementrelationship of the elastic members 202 may be appropriately selecteddepending on the type of the elastic member 202 and the magnitude of thepressure applied to the stage 201.

The body unit 203 may include the outer-bending forming portion 213 anda fixing portion 223. The outer-bending forming portion 213 is disposedat a vertex on the plane of the body portion 203 and includes innersurface 213-LS having a rounded or curved shape. The inner surface213-LS of the outer-bending forming portion 213 may have a shapecorresponding to the shape of the third pressing portion 101-3 of theupper mold 100 described above. In FIGS. 3A and 3B, the outer-bendingforming portion 213 and the fixing portion 223 may have a single unitaryform, however, the outer-bending forming portion 213 and the fixingportion 223 may be separate components having independent shapes.

The stage 201 and the elastic member 202 are placed on the fixingportion 223, and the fixing portion 223 holds the stage 201 to move upand down along the third direction DR3 without being misaligned when thestage 201 is pressed by the upper pressing member 101. A predeterminedinner space is defined in a center of the fixing portion 223, and thestage 201 and the elastic member 202 are placed in the predeterminedinner space.

The lower mold 200 may further include a guide bush for the alignmentwith the upper mold when the target panel is pressed by the upper mold100 described above.

FIG. 4A is a perspective view of an exemplary embodiment of the sidemold 300 of the bending panel manufacturing apparatus of FIG. 1A. FIG.4B is a front view of an exemplary embodiment of the side mold 300 ofthe bending panel manufacturing apparatus of FIG. 1A. FIG. 4C is a sideview of an exemplary embodiment of the side mold 300 of the bendingpanel manufacturing apparatus of FIG. 1A. FIG. 4D is a front view of anexemplary embodiment of a side mold of a bending panel manufacturingapparatus of FIG. 1A.

Referring to FIGS. 4A to 4C, the side mold 300 includes a pair of thefirst side molds 310 and 320 spaced apart from each other in the firstdirection DR1 and extending in the second direction DR2 and a pair ofthe second side molds 330 and 340 spaced apart from each other in thesecond direction DR2 and extending in the first direction DR1. The firstside molds 310 and 320 are spaced apart from each other in the firstdirection DR1. The second side molds 330 and 340 are spaced apart fromeach other in the second direction DR2.

The pair of first side molds 310 and 320, and the pair of second sidemolds 330 and 340 include the respective side pressing members 311, 321,331, and 341, the respective side plates 312, 322, 332, and 342, therespective second moving units 313, 323, 333, and 343, respective sideheating heaters 314, 324, 334, and 344, and respective side temperaturesensors is 315, 325, 335, and 345.

The side pressing members 311, 321, 331, and 341 may be respectivelyconnected to one ends of the side plates 312, 322, 332, and 342 and mayhave a cross-sectional shape that decreases in a direction away from theside plates 312, 322, 332, and 342. The cross-sectional shape of theside pressing members 311 and 321 of the first side molds 310 and 320decreases in a direction away from the side plates 312 and 322 in thefirst direction DR1. The cross-sectional shape of the side pressingmembers 331 and 341 of the second side molds 330 and 340 decreases in adirection away from the side plates 332 and 342 in the second directionDR2.

The side pressing members 311, 321, 331, and 341 may respectivelyinclude upper surfaces 311-US, 321-US, 331-US, and 341-US and mayrespectively include side surfaces 311-LS, 321-LS, 331-LS, and 341-LS.The upper surfaces 311-US, 321-US, 331-US, and 341-US of the sidepressing members 311, 321, 331, and 341 may support an outer portion ofthe target panel when the target panel is placed on the stage. The sidesurfaces 311-LS, 321-LS, 331-LS, and 341-LS of the side pressing members311, 321, 331, and 341 may be surfaces that substantially press thetarget panel as the side mold 300 moves.

The side surfaces 311-LS, 321-LS, 331-LS, and 341-LS of the sidepressing members 311, 321, 331, and 341 may be inclined ata second slopewith respect to the upper surfaces 311-US, 321-US, 331-US, and 341-US.The side surfaces 311-LS, 321-LS, 331-LS, and 341-LS of the sidepressing members 311, 321, 331, and 341 may have the second slopeinclined by a second angle θ2 with respect to the upper surfaces 311-US,321-US, 331-US, and 341-US. The second angle θ2 may be an acute angle.That is, the second angle θ2 may be smaller than about 90 degrees.

The second slope may be substantially the same as the first slope of theupper is pressing member. That is, the second angle θ2 may be the sameas the first angle θ1 (refer to FIG. 3C) between the side surface andthe lower surface of the upper pressing member. The side pressingmembers 311, 321, 331, and 341 may have the shape corresponding to thatof the upper pressing member. The side surfaces 311-LS, 321-LS, 331-LS,and 341-LS of the side pressing members 311, 321, 331, and 341 may besubstantially parallel to the side surface 101-LS1, 101-LS2 of the upperpressing member.

The side plates 312, 322, 332, and 342 may perform a function of fixingthe positional relationships between the components included in the sidemold 300, e.g., the side pressing members 311, 321, 331, and 341, thesecond moving units 313, 323, 333, and 343, the side heating heaters314, 324, 334, and 344, and the side temperature sensors 315, 325, 335,and 345. In FIGS. 4A to 4C, the side pressing members 311, 321, 331, and341 may be provided integrally with the side plates 312, 322, 332, and342, however, the side pressing members 311, 321, 331, and 341 may beseparated formed from the side plates 312, 322, 332, and 343 to haveindependent shapes.

The second moving units 313, 323, 333, and 343 may be disposed outsideof the side plates 312, 322, 332, and 342 and may move the side mold 300left and right along the first direction DR1 or the second directionDR2. The second moving units 313, 323, 333, and 343 may move the sidemold 300 left and right along the first direction DR1 or the seconddirection DR2 using a pneumatic or hydraulic cylinder, or other knownmeans. As another way, the second moving units 313, 323, 333, and 343may move the side mold 300 left and right along the first direction DR1or the second direction DR2 using a mechanical cylinder.

The side heating heaters 314, 324, 334, and 344 may be connected to theside plates 312, 322, 332, and 342 and may apply heat to the side plates312, 322, 332, and 342 such is that the side pressing members 311, 321,331, and 341 thermoforms the target panel using the heat appliedthereto. When the side heating heaters 314, 324, 334, and 344 apply heatto the side plates 312, 322, 332, and 342, the side temperature sensors315, 325, 335, and 345 connected to the side plates 312, 322, 332, and342 may adjust the temperature to be suitable for thermoforming thetarget panel.

Referring to FIG. 4D, side molds 310-1 and 320-1 may further includeauxiliary pressing members 316 and 326. The auxiliary pressing members316 and 326 may be disposed under side pressing members 311-1 and 321-1and may be connected to side plates 312 and 322. As the side molds 310-1and 320-1 include the auxiliary pressing members 316 and 326, the targetpanel may be prevented from sagging downward when the side molds 310-1and 320-1 move in the first direction DR1 and press the target panel. Inaddition, an upper mold and the side molds 310-1 and 320-1 may beengaged with each other due to the shape of the auxiliary pressingmembers 316 and 326 when the target panel is pressed.

FIG. 5 is a top view of an exemplary embodiment of some components ofthe bending panel manufacturing apparatus of FIG. 1A. FIG. 5schematically shows the lower mold 200 and the side molds 310, 320, 330,and 340 of the bending panel manufacturing apparatus of FIG. 1.

Referring to FIG. 5, the side molds 310, 320, 330, and 340 of thebending panel manufacturing apparatus may be disposed to correspond toedges of the lower mold 200. The first side molds 310 and 320 may bedisposed with the lower mold 200 interposed therebetween to be spacedapart from each other in the first direction DR1 and may extend in thesecond direction DR2. The second side molds 330 and 340 may be disposedwith the lower mold 200 interposed therebetween to be spaced apart fromeach other in the second direction DR2 and may is extend in the firstdirection DR1.

The longitudinal lengths of the side molds 310, 320, 330, and 340 mayrespectively correspond to length of the edges of the stage 201 of thelower mold 200. The first side molds 310 and 320 may extend in thesecond direction DR2 by the same length as the second length d2 that isthe length of the edge in the second direction DR2 of the stage 201. Thesecond side molds 330 and 340 may extend in the first direction DR1 bythe same length as the first length d1 that is the length of the edge inthe first direction DR1 of the stage 201.

FIG. 6A is a cross-sectional view of another exemplary embodiment of abending panel manufacturing apparatus 10-2 constructed according to theprinciples of the invention in a first direction. FIG. 6B is across-sectional view of the bending panel manufacturing apparatus 10-2of FIG. 6A taken in a second direction normal to the first direction.Hereinafter, different features of the bending panel manufacturingapparatus 10-2 from the bending panel manufacturing apparatus 10 shownin FIGS. 1A and 1B will be mainly described.

Referring to FIGS. 6A and 6B, the bending panel manufacturing apparatus10-2 includes a first mold 200-2, a second mold 100-2, and a third mold300-2. The descriptions of the lower mold 200 described in FIGS. 1A and1B may be applied to each component of the first mold 200-2. Thedescriptions of the upper mold 100 described in FIGS. 1A and 1B may beapplied to each component of the second mold 100-2. The descriptions ofthe side mold 300 described in FIGS. 1A and 1B may be applied to eachcomponent of the third mold 300-2.

The bending panel manufacturing apparatus 10-2 shown in FIGS. 6A and 6Bmay have a structure in which the upper mold and the lower mold aresubstantially inverted to each other in the bending panel manufacturingapparatus 10 shown in FIGS. 1A and 1B. That is, the first mold 200-2 isdisposed above the second mold 100-2 in the third direction DR3. Thethird is mold 300-2 may be disposed at both sides of the first mold200-2 in the first direction DR1 and the second direction DR2.

Contrary to FIGS. 1A and 1B, according to the bending panelmanufacturing apparatus 10-2 shown in FIGS. 6A and 6B, since the secondmold 100-2 is disposed at a lower side in the third direction DR3, thetarget panel may be placed on the second mold 100-2, and then thebending process may proceed. The target panel may be placed on a firstpressing member 101-2 of the second mold 100-2, the second mold 100-2may move upward due to an operation of a first moving unit 103-2, andthus the target panel may be primarily pressed between a stage 201-2 ofthe first mold 200-2 and the first pressing member 101-2. Then, thetarget panel that is primarily pressed may be secondarily pressed bysecond pressing members 311-2, 321-2, 331-2, and 341-2 included in thethird mold 300-2.

In FIGS. 6A and 6B, the second mold 100-2 moves upward along the thirddirection DR3 due to the operation of the first moving unit 103-2 toprimarily press the target panel, however, it should not be limitedthereto or thereby. That is, a moving unit that moves a mold in thethird direction DR3 may be included in the first mold 200-2 and thethird mold 300-2. In this case, the operation of primarily pressing thetarget panel may be performed by moving the first mold 200-2 and thethird mold 300-2 along the third direction DR3 by the moving unitconnected to the first mold 200-2 and the third mold 300-2.

Hereinafter, a bending panel according to an exemplary embodiment willbe described with reference to accompanying drawings.

FIG. 7A is a perspective view of an exemplary embodiment of a bendingpanel 1000 constructed according to the principles of the invention in asubstantially flat, planar state. FIG. 7B is a perspective view of thebending panel 1000 of FIG. 7A in a bent state. FIG. 7C is a is frontview of the bending panel 1000 of FIG. 7B. FIG. 7D is a side view of thebending panel 1000 of FIG. 7B. FIG. 7A shows a planar state of thebending panel 1000 before the bending panel 1000 is bent. FIGS. 7B to 7Dshow the bending panel 1000 in the bent state. FIG. 7E is a perspectiveview of an exemplary embodiment of a bending panel 1000-1 constructedaccording to the principles of the invention in a substantially flat,planar state.

Referring FIGS. 7A to 7D, the bending panel 1000 may be a any member tobe applied to a display device, such as a protective film. In anexemplary embodiment, the bending panel 1000 may be the protective filmthat is disposed on one surface (e.g. bottom surface) of a display panelof the display device and protects the display panel.

The bending panel 1000 includes a flat portion 1100 and bending portions1210, 1220, and 1300. The flat portion 1100 is disposed at a center ofthe bending panel 1000, and the bending portions 1210, 1220, and 1300are disposed to surround an edge of the flat portion 1100.

The flat portion 1100 is substantially parallel to a plane defined bythe first direction DR1 and the second direction DR2. In the exemplaryembodiment, the flat portion 1100 has a substantially rectangular shapewith curved vertices, however, it should not be limited thereto orthereby. That is, the flat portion 1100 may have various shapesdepending on a shape of the display device to which the bending panel1000 is applied.

The bending portions 1210, 1220, and 1300 may include first bendingportions 1210, second bending portions 1220, and third bending portions1300. The first bending portions 1210 may extend in the second directionDR2 and may be disposed to be spaced apart from each other in the firstdirection DR1 with the flat portion 1100 interposed therebetween. Thesecond bending portions 1220 may extend in the first direction DR1 andmay be disposed to be spaced apart from each other in the seconddirection DR2 with the flat portion 1100 interposed is therebetween. Thethird bending portions 1300 may be disposed between the first bendingportions 1210 and the second bending portions 1220 and may be disposedat vertices of the flat portion 1100. In the bent state of the bendingpanel 1000, the height in the third direction DR3 of the third bendingportions 1300 may be smaller than the height in the third direction DR3of the first bending portions 1210 and the second bending portions 1220.

In the bent state of the bending panel 1000, the first bending portions1210 and the second bending portions 1220 may be bent upward. The firstbending portions 1210 and the second bending portions 1220 may be bentin an upward direction of the bending panel 1000 along the thirddirection DR3. In the bending panel 1000, the first bending portions1210 and the second bending portions 1220 may be bent by about 90degrees or more. For example, the angles of the first bending portions1210 and the second bending portions 1220 may be “180-θ4” degrees asshown in FIG. 7C. That is, a fourth angle θ4 between the flat portion1100 and the first bending portion 1210 and between the flat portion1100 and the second bending portion 1220 may be smaller than about 90degrees as shown in FIG. 7C. The bending panel 1000 may be bent by theabove-described bending panel manufacturing apparatus, and the fourthangle θ4 between the flat portion 1100 and the first bending portion1210 and between the flat portion 1100 and the second bending portion1220 may be substantially the same as the first angle θ1 between theside surface 101-LS and the lower surface 101-US of the upper pressingmember 101 (refer to FIG. 2C) of the bending panel manufacturingapparatus.

In the bent state of the bending panel 1000, the third bending portions1300 may have a curved or rounded shape. The third bending portions 1300may be disposed between the first bending portions 1210 and the secondbending portions 1220 to have the rounded shape. The bending panel 1000may be bent by the above-described bending panel manufacturing isapparatus, and the bent shape of the third bending portions 1300 maycorrespond to the round shape of the third pressing portion 101-3 of theupper pressing member 101 (refer to FIG. 2B) and the round shape of theouter-bending forming portion 213 of the lower mold 200 of the bendingpanel manufacturing apparatus.

A plurality of slits SL1 and SL3 may be defined between the firstbending portions 1210 and the third bending portions 1300 and betweenthe second bending portions 1220 and the third bending portions 1300.The third bending portions 1300 may include a first sub-bending portion1310 and a second sub-bending portion 1320, and a plurality of slits SL2may be defined between the first sub-bending portion 1310 and the secondsub-bending portion 1320. As the slits SL1, SL2, and SL3 are definedbetween the first bending portions 1210 and the third bending portions1300, between the second bending portions 1220 and the third bendingportions 1300, and between the first and second sub-bending portions1310 and 1320, the first, second, and third bending portions 1210, 1220,and 1300 may be bent without overlapping with each other when thebending panel 1000 is bent. In particular, the vertex portions of thebending panel 1000 may be effectively bent.

Referring to FIG. 7E, a slit is not defined in the bending panel 1000-1,and a third bending portion 1300-1 having a single unitary shape may bedisposed between the first bending portion 1210 and the second bendingportion 1220. Although the slit is not defined in the bending panel1000-1, when the third bending portion 1300-1 of the bending panel1000-1 is pressed by the third pressing portion 101-3 of the upperpressing member 101 (refer to FIG. 2B) and the outer-bending formingportion 213 of the lower mold 200 of the bending panel manufacturingapparatus, the material of the bending panel 1000-1 may be stretched andthe third bending portion 1300-1 may have the round shape.

Hereinafter, an exemplary method of manufacturing the display devicewill be described with reference to figures.

The exemplary manufacturing method of the display device includescoupling the display panel to a first portion (e.g., lower portion) of awindow member and coupling the protective film to a first portion (e.g.,lower portion) of the display panel. The steps of coupling theprotective film include the steps of bending both ends of the protectivefilm, disposing the bent protective film on the lower portion of thedisplay panel, and coupling the display panel to the protective film.

FIGS. 8A to 8I are cross-sectional views of an exemplary embodimentsequentially showing an exemplary method of manufacturing the displaydevice according to the principles of the invention. FIGS. 8A to 8Fsequentially show the steps of bending the protective film of themanufacturing method of the display device. FIG. 8G schematically showsa cross-section corresponding to a line I-I′ of FIG. 3C in the step ofbending the protective film of the manufacturing method of the displaydevice. FIGS. 8H and 8I show the steps of disposing the bent protectivefilm on the lower portion of the display panel of the manufacturingmethod of the display device.

FIGS. 8A to 8C sequentially show the step of bending the protective filmwhen viewed in a cross-section corresponding to the plane defined by thefirst direction DR1 and the third direction DR3. FIGS. 8D to 8Fsequentially show the step of bending the protective film when viewed ina cross-section corresponding to the plane defined by the seconddirection DR2 and the third direction DR3. Hereinafter, the step ofbending the protective film will be described with reference to FIGS. 8Ato 8F.

Referring to FIGS. 8A and 8D, the manufacturing method of the displaydevice is includes the step of disposing the target panel 1000 on thestage 201. In the manufacturing method of the display device, the targetpanel 1000 may be the protective film applied to the display device. Inthe exemplary embodiment, the target panel 1000 may be the protectivefilm disposed on a first surface (e.g. bottom surface) of the displaypanel of the display device to protect the display panel. When thetarget panel 1000 is placed on the stage 201, an outer portion of thetarget panel 1000 may be placed on some of the side molds 310, 320, 330,and 340.

Referring to FIGS. 8A, 8B, 8D, and 8E, the manufacturing method of thedisplay device includes the step of pressing the upper portion of thetarget panel 1000 using the upper pressing member 101. The upperpressing member 101 may move downward by the operation of the firstmoving unit 103 and may press the upper portion of the target panel1000. As the upper pressing member 101 presses the upper portion of thetarget panel 1000, the elastic member 202 disposed under the stage 201may be compressed, and the stage 201 may move downward.

In the step of pressing the upper portion of the target panel 1000 usingthe upper pressing member 101, the outer portion of the target panel1000 may be bent by a bending angle of “180-θ3” to form the target panel1000-P1 with a third angle θ3. The outer portion of the target panel1000 may be primarily bent by the upper pressing member 101 such thatthe angle between the bent portion and the flat portion becomes thethird angle θ3. The third angle θ3 may be greater than the first angleθ1 of the corner of the upper pressing member 101. In the step ofpressing the upper portion of the target panel 1000 using the upperpressing member 101, the heater 104 may provide heat to the upper plate102 connected to the upper pressing member 101, and the target panel1000 may be thermoformed by the heat provided to the upper pressingmember 101.

Referring to FIGS. 8B, 8C, 8E, and 8F, the manufacturing method of thedisplay is device includes the step of pressing the bending portion ofthe target panel 1000, which is primarily bent, using the side pressingmembers 311, 321, 331, and 341. The side pressing members 311, 321, 331,and 341 move to the stage 201 by the step of the second moving units313, 323, 333, and 343 and press the bent side surface of the targetpanel 1000 that is primarily bent.

In the step of pressing of the bending portion of the target panel 1000,which is primarily bent, using the side pressing members 311, 321, 331,and 341, the outer portion of the target panel 1000 may be bent by abending angle of “θ3-θ4” to form the target panel 1000-P2 with thefourth angle θ4. The outer portion of the target panel 1000 may beprimarily bent by the upper pressing member 101 and may be secondarilybent by the side pressing members 311, 321, 331, and 341, and thus theangle between the bent portion and the flat portion may become thefourth angle θ4. The fourth angle θ4 may be smaller than the third angleθ3 that is obtained after the primary bending. The fourth angle θ4 maybe substantially the same as the first angle θ1 of the corner of theupper pressing member 101. The fourth angle θ4 may be smaller than about90 degrees. In the step of pressing of a side portion of the targetpanel 1000 using the side pressing members 311, 321, 331, and 341, theheater 314, 324, 334, and 344 may provide the heat to the side plates312, 322, 332, and 342 connected to the side pressing members 311, 321,331, and 341, and the target panel 1000 may be thermoformed by the heattransferred to the side pressing members 311, 321, 331, and 341.

Referring to FIG. 8G, the vertex portions of the target panel 1000 maybe bent by the upper pressing member 101 and the outer-bending formingportion 213 of the lower mold in the exemplary manufacturing method ofthe display device. In detail, the third pressing portion 101-3 (referto FIG. 2B) of the upper pressing member 101 and the outer-bendingforming is portion 213 (refer to FIG. 3B) may have rounded shapescorresponding to each other. In the vertex portions of the target panel1000, the third bending portion 1300 of the target panel 1000 disposedbetween the third pressing portion 101-3 and the outer-bending formingportion 213 may be bent to have the rounded shape by the shape of thethird pressing portion 101-3 and the outer-bending forming portion 213that are engaged with each other.

Referring to FIGS. 8H and 8I, the target panel bent by the bending panelmanufacturing apparatus may be coupled to the window member 2000 and thedisplay panel 3000. The target panel may be a protective film 1000-P3that protects the display panel 3000. Referring to FIG. 8H, theprotective film 1000-P3 may be bent by a bending angle of about 90degrees or more by the bending panel manufacturing apparatus, and thefourth angle θ4 formed between the flat portion and the bending portionof the protective film 1000-P3 may be smaller than about 90 degrees. Theouter portion of the window member 2000 and the outer portion of thedisplay panel 3000 may be bent by a bending angle of relatively smallerangle than the protective film 1000-P3. In the exemplary embodiment, thewindow member 2000 and the display panel 3000 may be bent by a bendingangle of about 90 degrees. A fifth angle θ5 between the bending portionand the flat portion of each of the window member 2000 and the displaypanel 3000 may be about 90 degrees. The fifth angle θ5 between thebending portion and the flat portion of each of the window member 2000and the display panel 300 may be greater than the fourth angle θ4. Theprotective film 1000-P3 bent at the fourth angle θ4 may be disposedunder the display panel 3000 and may be attached to the display panel3000 by being pressed using a roller. Referring to FIG. 8I, in thedisplay device DS to which the protective film 1000 is attached, theprotective film 1000 may be stretched to allow the bending angle of theprotective film 1000 to correspond to the bending angle of the windowmember 2000 and the is display panel 3000.

In the exemplary manufacturing method of the display device, theprotective film is bent by the bending panel manufacturing apparatusbefore the protective film is coupled to the lower portion of thedisplay panel, and the bent protective film is coupled to the lowerportion of the display panel. In more detail, the display panel and thewindow member are bent by a predetermined angle, the protective film isbent by a bending angle greater than the bending angle of the displaypanel and the window member, and then the protective film is coupled tothe lower portion of the display panel.

In a case where the protective film is coupled to the display panel andthe window member without being bent, the display panel and theprotective film may be separated from each other by the repulsive forceof the material of the protective film, and the reliability of thedisplay panel is reduced. According to the exemplary manufacturingmethod of the display device, since the protective film is pre-bentbefore being coupled to the lower portion of the display panel, theprotective film may be prevented from being separated from the displaypanel even though the protective film is coupled to the display panelhaving a curvature, and thus the reliability of the display device maybe improved. In particular, since the protective film is coupled to thedisplay panel and the window member after being bent by the anglegreater than the bending angle of the display panel and the windowmember, the separation of the protective film due to the repulsive forceof its material may be minimized.

FIGS. 9A, 9B, and 9C are cross-sectional views sequentially showing somesteps of another exemplary method of manufacturing the display deviceaccording to the principles of the invention. FIGS. 9A to 9C show theprocess of bending the protective film of the method of manufacturingthe display device. In FIGS. 9A to 9C, the same reference numeralsdenote the same elements in FIGS. 1A to 8I, and thus detaileddescriptions of the same elements will be omitted. The protective film1001 and the cover film 4000 as shown in FIG. 9A is primarily bent toform the protective film 1001-P1 and the cover film 4000-P1 as shown inFIG. 9B, and then secondarily bent to form the protective film 1001-P2and the cover film 4000-P2 as shown in FIG. 9C.

Referring to FIGS. 9A to 9C, the manufacturing method of the displaydevice may include the step of disposing a cover film (e.g., releasefilm) 4000 under a protective film 1001 before the protective film 1001is placed on a stage 201. In FIGS. 9A to 9C, the cover film 4000 isdisposed only under the protective film 1001, however, it should not belimited thereto or thereby. The cover film 4000 may be also disposed onthe protective film 1001.

The cover film 4000 may prevent the protective film 1001 from beingdamaged in the operation of bending the protective film 1001 and mayprevent the protective film 1001 from being attached to the bendingpanel manufacturing apparatus due to an adhesive force of the protectivefilm 1001. As the cover film 4000 is disposed under and/or on theprotective film 1001, the upper pressing member 101 and the sidepressing members 311 and 321 may press the cover film 4000 to bend theprotective film 1001 without directly pressing the protective film 1001.The cover film 4000 may be removed after the protective film 1001 isbent using the bending panel manufacturing apparatus and before theprotective film 1001 is coupled to the lower portion of the displaypanel.

FIG. 10 is a cross-sectional view showing a step of still anotherexemplary method of manufacturing a display device according to theprinciples of the invention. FIG. 10 shows the step of pressing aprotective film by side molds 310 and 320 to bend the protective film ofthe manufacturing method of the display device. In FIG. 10, the samereference numerals is denote the same elements in FIGS. 1A to 9C, andthus detailed descriptions of the same elements will be omitted to avoidredundancy.

Referring to FIG. 10, in the step of pressing a side portion of a targetpanel 1000 using side pressing members 311 and 321 of the manufacturingmethod of the display device, the side molds 310 and 320 do not moveleft and right along the first direction DR1 but rotate about rotatingshafts 317 and 327 to press the side portion of the target panel 1000.That is, when the side molds 310 and 320 may rotate about the rotatingshafts 317 and 327, the side pressing members 311 and 321 maysecondarily press the side portion of the target panel 1000, which isprimarily bent. In this case, since upper surfaces of the side pressingmembers 311 and 321 do not support the target panel 1000 before thesecond pressing operation, the bending panel manufacturing apparatus mayfurther include a supporter 500 that supports an outer portion of thetarget panel 1000.

Although certain exemplary embodiments and implementations have beendescribed herein, other embodiments and modifications will be apparentfrom this description. Accordingly, the inventive concepts are notlimited to such embodiments, but rather to the broader scope of theappended claims and various obvious modifications and equivalentarrangements as would be apparent to a person of ordinary skill in theart.

What is claimed is:
 1. An apparatus for manufacturing a bending panel ofa display device, the apparatus comprising: a lower mold having a firstmember on which a target panel is placed; an upper mold disposedadjacent the lower mold and comprising a second member having a firstsurface to press a portion of the target panel and a second surfacehaving a first slope with respect to the first surface; and side moldsdisposed at opposite sides of the lower mold and each having a thirdmember with a third surface complementary to the second surface of thesecond member, wherein the first slope is smaller than about 90 degrees.2. The apparatus of claim 1, wherein the first member comprises a stagehaving a receiving portion substantially parallel to a plane defined bya first direction and a second direction intersecting the firstdirection, and the side molds comprise: a pair of first side moldsspaced apart from each other in the first direction, and disposed at theopposite sides of the lower mold to press the target panel in the firstdirection; and a pair of second side molds spaced apart from each otherin the second direction, and disposed at the both sides of the lowermold to press the target panel in the second direction.
 3. The apparatusof claim 2, wherein the upper mold is spaced apart from the lower moldin a third direction intersecting the first direction and the seconddirection, and the upper mold is configured to press the target panel inthe third direction.
 4. The apparatus of claim 3, wherein the secondmember comprises an upper pressing member having a cross sectional shapewith an area in a plan view that increases as the distance in the thirddirection from the lower mold decreases.
 5. The apparatus of claim 2,wherein the second member comprises: a first pressing portion extendingin the first direction; a second pressing portion extending in thesecond direction; and a third pressing portion disposed between thefirst pressing portion and the second pressing portion and having arounded shape.
 6. The apparatus of claim 5, wherein the lower moldfurther comprises an outer-bending forming portion configured to overlapwith the third pressing portion in the plane defined by the firstdirection and the second direction, and the outer-bending formingportion has a shape complementary to the rounded shape of the thirdpressing portion.
 7. The apparatus of claim 1, wherein the third membercomprises: an upper surface supporting an outer portion of the targetpanel; and a side surface to press the target panel and having a secondslope with respect to the upper surface, and the second slope is smallerthan about 90 degrees.
 8. The apparatus of claim 7, wherein the firstslope and the second slope are substantially the same.
 9. The apparatusof claim 1, wherein the upper mold further comprises a first portion tomove the second member up and down, and the side molds further comprisea second portion to move the side pressing member left and right. 10.The apparatus of claim 1, wherein the lower mold further comprises oneor more biasing members disposed under the first member, the one or morebiasing members being compressed when the second member presses againstthe target panel.
 11. The apparatus of claim 1, wherein the upper moldfurther comprises: an upper plate supporting the second member; and anupper heater connected to the upper plate to apply a heat to the upperplate.
 12. The apparatus of claim 1, wherein the side molds furthercomprise: a side plate supporting the third member; and a side heaterconnected to the side plate and to apply heat to the side plate.
 13. Anapparatus for manufacturing a bending panel, the apparatus comprising: afirst mold including a first member having a first surface substantiallyparallel to a plane defined by a first direction and a second directionintersecting the first direction; a second mold spaced apart from thefirst mold in a third direction intersecting each of the first andsecond directions and including a second member having a second surfacesubstantially parallel to the first surface and a third surface having aslope with respect to the second surface that is less than about 90degrees; and a third mold spaced apart from the first mold in the firstdirection and the second direction and comprising a third member havinga fourth surface complementary to the third surface.
 14. A method ofmanufacturing a display device, the method comprising the steps of:coupling a display panel to a first portion of a window member; andcoupling a protective film to a lower portion of the display panel, thestep of coupling of the protective film further comprising the steps of:bending both edges of the protective film by a bending angle of about 90degrees or more; disposing the bent protective film on the lower portionof the display panel; and coupling the protective film to the displaypanel,
 15. The method of claim 14, wherein the step of bending of theboth edges of the protective film further comprises the steps of:placing the protective film on a support; pressing an upper portion ofthe protective film to bend the both edges at a first angle; andpressing a side portion bent at the first angle to bend the both edgesat a second angle smaller than the first angle.
 16. The method of claim15, wherein an elastic member is disposed under the support, and whereinthe step of pressing of the upper portion of the protective filmcomprises compressing the elastic member.
 17. The method of claim 15,wherein the step of pressing of the upper portion of the protective filmfurther comprises the step of indirectly applying heat to the upperportion of the protective film.
 18. The method of claim 15, wherein thestep of pressing of the side portion of the protective film furthercomprises the step of indirectly applying heat to the side portion ofthe protective film.
 19. The method of claim 15, wherein the step ofpressing of the side portion of the protective film is performed byhorizontally moving one or more side pressing members or by rotating theone or more side pressing members.
 20. The method of claim 15, whereinthe step of bending of the both edges of the protective film furthercomprises the steps of: disposing a release film under the protectivefilm before the placing the protective film on the support; and removingthe release film before coupling the display panel to the protectivefilm.
 21. The method of claim 15, further comprising, before the step ofcoupling of the lower portion of the display panel to the protectivefilm, bending outer portions of the window member and the display panelat a third angle greater than the second angle at which the protectivefilm is bent.
 22. A protective film for a display device, the protectivefilm comprising: a substantially flat portion disposed substantiallyparallel to a plane defined by a first direction and a second directionintersecting the first direction; and a bent portion disposed at a sideof the substantially flat portion, the bent portion comprising: a firstportion extending in the first direction; and a second portion extendingin the second direction, wherein each of an angle between the firstportion and the substantially flat portion and an angle between thesecond bent portion and the substantially flat portion is less thanabout 90 degrees.
 23. The protective film of claim 22, wherein the bentportion further comprises a third bent portion disposed between thefirst bent portion and the second bent portion.
 24. The protective filmof claim 23, wherein the third bent portion is disposed between thefirst bent portion and the second bent portion and has a rounded shape.25. The protective film of claim 23, wherein a plurality of slits aredisposed between the first bent portion and the third bent portion andbetween the second bent portion and the third bent portion.